Abstract: A sensor for recording bioelectrical signals directly from hairy skin regardless of the amount or density of hair is fabricated using a polymer with an electrically conductive filler. The sensors have a stemmed conical microstructure array (CMSA) on the sensor surface that interfaces with and adheres to the skin between the hairs. The CMSA sensors are fabricated using a viscosity-controlled dip-pull process (VCDP), including dipping a mold into an electrically conductive polymer precursor having a selected viscosity that is optimized for formation of the conical microstructures upon a controlled pulling of the mold from the polymer precursor.